Aluminum Extrusion Troubleshooting

Flatness

Problem Description

The profile deviates from a flat plane across its width or length, affecting dimensional accuracy and assembly fit.

Cause–Correction Mapping
  • Bearing squareness
    Cause in: Die

      Corrections

    • Correct for square bearings; square the bearings perpendicular to the metal flow.

  • Inadequate flow in specific ports
    Cause in: Die, Profile

      Corrections

    • Mill/grind inadequate ports to adjust flow.

      Advantage: Replacement dies can be made with adjustments.

    • Shorten bearing lengths on slow areas.

    • Choke top and bottom bearings if delivery or last resort.

      Disadvantage: Die wears out more quickly with choked bearings; difficult to repeat on replacement dies.

Please note that the information provided in this article is intended to be a general guide to the causes and corrections of Flatness in aluminum extrusion. However, it is important to note that the specific cause and correction of any particular defect will vary depending on the specific extrusion process, alloy, and other factors. Therefore, it is important to consult with an experienced and professional engineer to ensure that the correct diagnosis is made and the most suitable correction is chosen.